Packing station for foldable carton handling apparatus

ABSTRACT

An automatic carton handling apparatus for erecting foldable cartons and positioning them adjacent to a packing machine of the kind which loads the cartons while they are resting on their side panels. The apparatus includes a feed magazine which feeds carton blanks from a stack to a loading station disposed below it, a reciprocating carriage for moving carton blanks from the loading station to a forming station, an opening mechanism for forming the cases into an essentially rectangular tubular configuration, pivotable arms for closing the bottom end flaps, rectilinear arms for closing the bottom side flaps, and a retractable pusher arm associated with the carriage for transferring the opened case from the forming station to a packing station. Included at the forming station is an arm for opening the leading top end flap of the opened carton and a flap flange for maintaining the flap in its opened position. The packing station has associated with it a pivoting carton positioning arm which pushes the opened carton against an end stop, an angular flanged packing horn, carton transfer arms for pushing the opened carton off the carriage onto the packing horn and a lowering arm which contacts the bottom of the carton on the packing horn and lowers the carton after it has been filled, to place the carton in an upright position on a conveyor. The apparatus is synchronized to sequentially feed the cartons in a downstream manner so that the cartons are opened, packed with canned goods, and moved downstream.

United States Patent [191 Berney [54] PAC KING STATION FOR FOLDABLE CARTON HANDLING APPARATUS [76] Inventor: Joseph C. Berney, 2700 Peterson Way 223, Costa Mesa, Calif. 92626 [22] Filed: Sept. 8, 1970 [21] Appl. No.: 70,460

[52] U.S. Cl ..53/186, 53/249 [51] Int. Cl. ..B6Sb 43/28 [58] Field of Search.....B65b/5/06; 53/186, 382, 243,

Primary Examiner-Travis S. McGehee Assistant Examiner-Horace M. Culver Att0rneyFowler, Knobbe & Martens [57] ABSTRACT An automatic carton handling apparatus for erecting 1 Apr. 3, 1973 foldable cartons and positioning them adjacent to a packing machine of the kind which loads the cartons while they are resting on their side panels. The apparatus includes a feed magazine which feeds carton blanks from a stack to a loading station disposed below it, a reciprocating carriage for moving carton blanks from the loading station to a forming station, an opening mechanism for forming the cases into an essentially rectangular tubular configuration, pivotable arms for closing the bottom end flaps, rectilinear arms for closing the bottom side flaps, and a retractable pusher arm associated with the carriage for transferring the opened case from the forming station to a packing station. Included at the forming station is an arm for opening the leading top end flap of the opened carton and a flap flange for maintaining the flap in its opened position. The packing station has associated with it a pivoting carton positioning arm which pushes the opened carton against an end stop, an angular flanged packing horn, carton transfer arms for pushing the opened carton off the carriage onto the packing horn and a lowering arm which contacts the bottom of the carton on the packing horn and lowers the carton after it has been filled, to place the carton in an upright position on a conveyor. The apparatus is synchronized to sequentially feed the cartons in a downstream manner so that the cartons are opened, packed with canned goods, and moved downstream.

9 Claims, 14 Drawing Figures PATENTEDAPR 3 ms sum OlUF 10 illll no 0 O O O O PATENTEBAPR3 ms SHEET UZUF 1O PATENTEDAPRQ 197s SHEET U30F 1O PATENTEU 3 1975 SHEET UHF 1O PATENTED R 3 7 SHEET 0 5 0F 10 PATENIEUAPR3 ma SHEET USUF 10 PATENTEDAPR 3, I973 SHEET U7UF 10 PATENTED 3 I975 SHEET UBUF 1O PATENTEU APR 3 I975 SHEET lUUF 1O Z w m M @W M W J M w W J w w. w a 4 $4 1 W 3 m 1 m m w r 1 ll T: Z M u m 1 m flap:T.@J.ili:: 1 u z E w J i. m M W? n M AM -1 0 1 y m M J. Z 3 2 r. I f g j a n HH 3 ,4. MI Ma a J h .7 .h or W WW, w 5 w w 5 w w ,0, w w

PACKING STATION FOR FOLDABLE CARTON HANDLING APPARATUS BACKGROUND OF THE INVENTION This invention relates to apparatus for setting up foldable cartons and packing them with goods.

Conventional folding shipping containers of the rectangular four-flap type are typically manufactured from a single piece of cardboard, corrugated board, or the like, cut into a predetermined pattern and provided with indented fold lines to facilitate the folding into a rectangular case or carton, the term carton" being used herein to designate a case of this type. The manufacturer usually folds the cardboard pattern once to bring two opposite edges together and then joins these two edges, such as with a strip of adhesive tape, for example, to firm what is commonly known as a manufacturers joint. When the carton is set up for use, the manufacturers joint is at a corner defined by the meeting of an end and a side of the carton. The cartons are shipped in this compact folded form commonly known in the art as the knocked down condition of the carton. These are also known as carton blanks. Each carton must be set up by opening it to a rectangular shape and then folding the bottom flaps inwardly to a closed position. The opened cartons are then typically moved out to a conveyor to supply downstream packing stations.

SUMMARY OF THE INVENTION The present invention is directed to the provision of such a packing station with a carton set up apparatus of the type described and claimed in my co-pending application, Ser. No. 70,566, filed on even date herewith, entitled HANDLING APPARATUS FOR FOLDABLE CARTONS. The carton set-up apparatus has a feeder mechanism where a plurality of horizontally disposed carton blanks are maintained in a vertical stack and a carriage, mounted for reciprocating movement, shuttles back and forth to transfer the bottom carton blank from a loading station under the stack to a forming station where it is opened and its bottom flaps are closed. The opened carton is then transferred downstream to a packing station where the opened carton is placed on a packing horn located to the rear of the packing station.

Vacuum cups at the forming station grip the upper side panel and lift it while restraining fingers, align with slots between the flaps on the upper side panel, act to partially restrain the bottom side panel. A break plate at the upstream end of the forming station strikes the trailing end panel of the carton blank as the upper side panel is being lifted so that, when the cups are fully withdrawn, the case is forced into a rectangular tubular configuration resting on its lower side panel, with its lowermost flaps facing toward the front of the forming station. Bottom end flap closing arms, positioned adjacent to their respective flaps have camming surfaces which pivot in and close the bottom end flaps, while bottom side flap closing members, one disposed above and one below their respective flaps, move rectilinearly to partially close the bottom side flaps.

After forming of the carton, transfer to the packing station is automatically accomplished by a pusher arm which is integrally mounted on the carriage and which engages the rear panel of the formed carton in the forming station and moves the carton to the packing station at the same time that the carriage moves another carton blank into the forming station from the loading station.

In accordance with a feature of the present invention, to insure that the leading top end flap does not become entangled with the packing horn while the carton is being transferred from the forming station to the packing station, elbows attached to the ends of the bottom end flap closing arms square the opened carton in the forming station, the forward elbow restraining the forward end panel, while means are used to bend the leading top end flap forward. The flap is maintained in its opened position by a pivoting flap flange for the initial portion of travel from the forming station to the packing station, and by a hinged lip depending at an angle from the upper edge of the packing horn to prevent the top flap from entering the horn during the balance of its travel to the packing station.

In order to accomplish the placing of the opened carton onto the packing horn and in accordance with a specific aspect of the invention, a carton positioning arm contacts the rear panel of the opened carton in the packing station and forces it against an end plate located at the downstream end of the packing station, aligning the opened carton so that a pair of case transfer arms may pull the case sideways off the carriage and onto the packing horn. The advantage here it that the carton, after opening, is automatically transferred to a position where it is pulled onto the horn without requiring human intervention.

The carriage is free to retract once the carton has been pushed off it. During this time another carton will have been opened in the forming station and the opened carton is restrained so that it is not dislocated while the pusher arm is cammed downward under the opened carton during the retraction of the carriage. After the carriage has been retracted, a lowering arm for holding the carton upon the horn swings up from a horizontal position under the packing station to a vertical position where it contacts the bottom of the carton. Then, when the goods to be packed have passed through the horn into the opened carton, the weight of the packed carton forces the arm downward to deposit the carton on a conveyor which takes the carton away, the lowering of the arm enabling the automatic sequence of the carton opening and transfer to proceed again.

BRIEF DESCRIPTION OF THE DRAWINGS The present invention and its advantages will be more clearly understood with reference to the following description of a preferred embodiment thereof taken in conjunction with the accompanying drawings in which:

FIG. 1 is a front elevation view of the carton handling apparatus with a stack of carton blanks in the feeder;

FIG. 2 is a plan view of the apparatus with carton blanks in the feeder;

FIG. 3 is a sectional view on the line 3-3 of FIG. 2;

FIG. 4 is a sectional view on the centerline of the carton transfer carriage;

FIG. 5 is a sectional view on the line 5-5 of FIG. 2 with an opened carton in the forming station;

FIG. 6 is a sectional view on the line 6-6 of FIG. 2 with a case in the forming station;

FIG. 7 is a sectional view on the same line of FIG. 6 just after the case has been moved out of the forming station into the packing station and onto the horn;

FIG. 8 is a sectional view on the same line as FIG. but after the flaps are closed",

FIG. 9 is a partial view of the top leading flap opening mechanism and the flap flange mechanism for holding the flap open, with the upper portion of the structure stipped away;

FIG. 10 is a partial pictorial view of the carton after transfer onto the packing horn with the lowering arm in its upward position; I

FIG. 11 is a pictorial view of the packing horn and the associated carton lowering arm;

FIG. 12 is a sectional view of the hinged lip of the packing horn on the line 12I2 of FIG. 11',

FIG. 13 is a perspective view of the working parts of the apparatus with the structure stripped away; and

FIG. 14 is a schematic of the preferred control circult.

In order to facilitate the understanding of the apparatus which is illustrated herein, there will first be given a general description of the entire apparatus followed by a detailed description of the structure of the apparatus so as to highlight those features of the invention which reside therein. Finally, in connection with the operation of the apparatus there will be described a pneumatic and electrical control system whereby all apparatus operations are carried out continuously and automatically.

STRUCTURE AND OPERATION OF AN EXEMPLARY APPARATUS INCORPORATING FEATURES OF THE INVENTION 1. In General The drawings show several views of a preferred embodiment of the foldable carton handling apparatus utilizing the present invention. Referring to FIGS. 1 and 2, for ease of explanation the apparatus may be functionally divided into a loading station 20, a forming station 22, and a packing station 24.

The various mechanisms of the exemplary apparatus associated with the loading station and the forming station 22 are supported in their desired relationship by a box-shaped framework, generally indicated by the reference numeral 26, as can best be seen in FIGS. 1 and 2 of the drawings. The framework 26 is defined by four vertically oriented leg members 28, between which four support beams 30 extend longitudinally. Six transverse braces 32, three on top and three on the bottom, complete the framework 26. To provide additional support and to serve as the mounting means for mechanisms associated with the forming station, two posts 27 (rear and front) extend between the upper and lower beams 30 in the vicinity of the center braces 32. To give support for the mechanisms associated with the packing station 24, the top support beams 30 are each provided with an extension 34. Rigidity is assured by a cross-brace 36 extending between the two extensions 34.

A case hopper 38 disposed above the loading station 20 acts as a receptacle for the folded carton blanks which are transferred by a reciprocating carriage 40 from the loading station 20 to the forming station 22 (shown in FIGS. 3 and 4) where they are opened and their flaps are closed, the carriage additionally acting to transfer the opened cartons from the forming station 22 to the packing station 24 so the opened cartons may be placed on a packing horn I32 and goods placed therein.

2. In Detail a. Case Hopper Referring to FIGS. 1, 2 and 3, the means for maintaining a plurality of horizontally disposed carton blanks in a vertical stack is provided by the case hopper 38. In order that the carton blanks may nestle within the case hopper 38 to be forced by gravity to the loading station 20 disposed directly below, the hopper is comprised of four vertically oriented staves 42 attached to the frame 26 so that the inner surfaces of each stave contacts one of the four corners of the carton blank, insuring a uniformly squared stack. For ease in placing additional carton blanks in the case hopper 28, the staves 42 are split a small distance down from their tops and bent outwardly so as to provide for a funnel-shaped entrance.

Maintaining the top of the staves 42 are support brackets 44 adjustably mounted on rails 46 which extend between the top beams 30, the adjustment being provided in order the carton blanks of varying lengths and widths may be used with the apparatus. Referring to FIG. 3, each stave 42 is attached at its bottom to, and is stiffened by, a fastening plate 48 which is in turn adjustably mounted to one of the bottom transverse braces 32. As the carton blanks are transferred from the loading station 20 under the case hopper 38 to the forming station 22, they are partially supported by a pair of guide brackets 50 which pass from under the case hopper into the forming station, the brackets being attached under the staves 42 to a pair of side beams 51 extending the length of the loading station and the forming station.

Since it is desired that only one carton blank be transferred from the case hopper 38 upon movement of the reciprocating carriage 40, two throat guides 52 are adjustably mounted to the downstream staves, defining a throat opening of variable width which, in addition to insuring transfer of only one carton at a time, allows the use of carton blanks of varying weight and thickness.

From the above description it can be seen that the carton blanks are guided by the staves 42 and urged by gravity toward the bottom of the case hopper 38 so as to be presented at the loading station 20 in a position where a single carton blank may be transferred to the forming station 22 by the reciprocating carriage 40.

b. Carton Transfer Carriage As alluded to above, the carton transfer means is a carriage 40 which functions to shuttle back and forth between the loading station 20 and the forming station 22, carrying a carton blank each time it moves forward. To this end the carriage 40 is mounted for reciprocating motion under the case hopper 38 so that its rear portion extends under the case hopper and its forward portion extends into the forming station 22. With reference to FIG. 3, the bottom panels of the carton blanks contact a carriage bed 54 which moves on rollers 56 in a pair of tracks 58 mounted on the frame 26, the movement being initiated by a two-way air actuated carton transfer cylinder 60.

The tracks 58 are formed by a pair of upright rails 62 extending parallel to the side beams 51 and mounted on base plates 64 attached to the bottom braces 32 to permit transverse adjustment between the staves 42. Each of the upright rails 62 carries a pair of rods 66 with rectangular cross-section, spaced apart sufficiently to accommodate the rollers 56.

Referring to FIGS. 3 and 4, the supporting portion of the carriage bed 54 is a downwardly extending channelshaped iron 68, to the outside of which are fastened the rollers 56 to support the carriage bed within the tracks 58. The rear portion of the carriage bed 54 which extends under the loading station 20, in addition to acting as a support for the carton blank, has an anchor plate 70 at its upstream edge which protrudes sufficiently above the level of the carriage bed to contact the trailing edge of a carton blank, causing it to be shifted downstream with the carriage bed 54. The anchor plate 70 is beveled at its rear edge so that, when the carriage bed 54 is retracted under the carton blanks in the feeder mechanism 38, the anchor plate will pass under them without catching.

Since a second function of the carriage 40 is to transfer an opened carton from the forming station 22 to the packing station 24, means are provided intermediate the carriage ends for engaging a formed carton, shown in FIGS. 4 and 13 as a latch-type pusher arm 72, which is inserted into the carriage bed 54 through a slot 74 and secured by a bushing 76 which is journaled to the channel 68. A cross piece 73 is attached to the outer end of the pusher arm 72 so as to provide a larger pushing surface against the rear panel of the opened carton. Since the carriage 40 retracts while an open carton is in the forming station 22, the pusher arm 72 must be free to turn downward to cam under the opened carton and then to assume its original upward position to transfer another opened carton. This is accomplished by a spring 78 round the bushing 76, with the spring being compressed between the button of the carriage bed 54 and a plate 80, attached beneath the bushing, to bias the pusher arm 72 into its upward position. To insure that the supporting portion of the carriage bed 54 is at least level with the crosspiece 73 when the latter is in its cammed-down position, a rear support plate 82 is attached to the carriage bed 54 just forward of the anchor plate 70 but of slightly less thickness so the anchor plate still may contact a carton blank. A forward support plate 84 is attached ahead of the pusher arm to maintain the height of the carriage bed 54 uniform.

The air cylinder 60 which causes the reciprocating movement of the carriage 40 is attached under the carriage bed 54 on the base plate 64, with its shaft 86 connected to the carriage bed through a bushing 88 and an L-shaped bracket 90 so that the shaft, as it extends and retracts, will move the carriage with it.

c. Forming Station Referring again to FIGS. 1 and 2, as the unopened carton blanks are transferred to the forming station 22, they are positioned essentially by the length of travel of the carriage 40, but a stop block 92 is attached near the downstream end of the forming station so as to contact the forward edge of the carton blank and insure that it does not move too far into the forming station.

(1) Carton Opening Mechanism Referring to FIGS. 2, 5, 6, and 7, the means for opening the carton is provided by a pair of vacuum cups 94 which are mounted in the forming station 22 so as to vertically descend and grip the top panel of the carton blank and to retract and open it. The cups 94 are attached to a member 96 which is guided in its vertical up and down motion by guide rods 98 inserted through guide bushings 100 supported by a mounting plate 102 extending between a pair of rails 104 which are fastened between the top support beams 30. The mounting plate 102 is adjustable so that the center line of the plate may be made to correspond with the center line of the carriage bed 54 in order to accommodate different size cartons. The vacuum for gripping is supplied to the cups 94 through a pair of hollow rods 106.

Vertical motion of the cups 94 is accomplished through the use of a double acting air cylinder 108 vertically attached between the guide rods 98 so that its shaft 110 may be connected to the leaf-shaped member 96, the cups 94 then descending and withdrawing upon extension and retraction of the shaft.

With reference to FIGS. 1, 6, and 7, as the upper side panel is being lifted, means at the forming station for striking the trailing end panel of the carton blank are provided by an angular break plate 111 installed at the upstream end of the forming station 22 between the posts 27. The striking of the trailing end of the carton as the cups 94 move upward assist in forming the carton into a rectangular, tubular configuration. To restrain the lower panel of the carton, a transversely extending retaining finger 112 is placed in the forming station so that the finger coincides with a slot between the flaps on the upper panel but engages the flaps on the lower panel.

(2) Bottom End Flap Closing Mechanism Referring to FIGS. 1, 5, and 8, the means provided for closing the bottom end flaps comprise a pair of camming arms 144 attached to the shafts of a pair of rotatable air cylinders 116 mounted in front of the forming station 22 so that, as the cylinders pivot inwardly, the camming arms rotate to fold the bottom flaps closed while a pair of elbows 118 located at the outer ends of the camming arms restrain and square the opened carton (See FIG. 9).

(3) Bottom Side Flap Closing Mechanism The means at the forming station for closing the bottom side flaps are shown in FIGS. 5 and 8. A pair of vertically spaced members 120 and 120a are mounted above and below the respective bottom side flaps and are movable toward one another to contact and partially close the bottom side flaps. The mounting and movement of the bottom side flap members is essentially the same as the operation of the case opening mechanism in that the members 102 and 120a are mounted on leaf-shaped members 122 and 122a whose vertical motion is guided by a pair of rods 124 and 124a which in turn are received by a pair of guide bushings 126 and 126a mounted on plates 128 and 128a extending between guide rails 104 and 104a. Vertical motion is achieved through a air of two-way air cylinders 130 and 130a vertically mounted between the guide rods 124 and 124a in the same manner as the case opening mechanism.

In order to prevent the opened carton from being dislocated when the carriage 40 retracts after the case is opened and the flaps are closed, the closing member 120a has a small projection 123 (shown in FIG. 13) attached at its rear end so as to contact the lowermost side flap and hold it while the carriage 40 retracts and the pusher arm 72 is pushed against it.

(4) Leading Top End Flap Opening and Restraining Mechanisms The packing horn 132 resides to the rear of the packing station 24 in close proximity to the travel of the opened carton so that it is necessary to insure that the leading top end flap is opened sufficiently so as to not become entangled with the packing horn. Referring to FIGS. 2 and 9, to this end a double acting two-way air cylinder 134 is mounted to intersect at an angle with the rear of the forming station 22 so that, as its shaft 136 extends, a knob 135 attached thereto opens the leading top end flap. For retaining the flap in its opened position while the carton is being transferred to the packing station, a flap flange 140 is mounted on the shaft 142 of a second two-way air cylinder 144 so that,

when the shaft is extended the flange will reside parallel to the line of travel of the carton, the flange pivoting about a point 146 so that at the desired time the flange 1 may be rotated backwardly to pull the flange away from the packing horn 132. d. Packing Station Once the carton blank has been formed and its flaps have closed, transfer is accomplished to the packing station 24 from the forming station 22 while a flap bracket 148 mounted between the forming station and the packing station on a pair of rails 1S0 guides and closes the bottom flaps in their essentially closed position. Forming of the carton having been accomplished, the mechanisms associated with the packing station 24 will insure that the carton is properly positioned to be packed with goods.

( 1) Carton Positioning Arm In order to position an opened carton in the packing station 24 for movement onto the packing horn 132, a carton positioning arm 152 is mounted at the upstream end of the packing station on the shaft of a pivotable air cylinder 154 so that the arm 152 may swing from a normally horizontally disposed position to a vertical position in which it contacts the rear of an opened carton and pushes the carton against an end plate 156. The pivotable cylinder 154 is mounted on the rails 150 in order to permit an adjustment to be made for differently sized cartons.

(2) Packing Horn Goods to be packed in the opened cartons will be directed from the packing equipment to the opened carton through the packing horn 132 which is generally rectangular with flared walls, is attached to the packing equipment, and is positioned to the rear of and adjacent to the packing station 24 as shown in FIG. 11. The front end of the horn 132 is of a shape and size to allow it to enter into a carton as the latter is pulled onto the horn. To keep the leading end flap of the carton out of the horn while the carton is being conveyed to its position opposite the born, the upper wall of the horn terminates in a hinged plate 158 which extends downward into the mouth of the horn, the plate being biased downwardly by a spring biased latch 159 and being free to swing out of the born into a horizontal position to permit unimpeded passage of goods into the carton.

(3) Case Transfer Arms In accordance with an aspect of the invention, means are provided for pushing the carton off the carriage 40 and onto the packing horn 132. Referring to FIGS. 2 and 10, in the exemplary embodiment disclosed herein this means comprises a pair of case transfer arms 160 which, in their normal positions, depend vertically near the front of the packing station 24 to contact the bottom of an opened carton and to move it directly onto the packing born, the arms in addition having means to cause them to pivot upwardly and away from the bottom of the carton after it has been positioned on the packing horn. The combined rectilinear and pivoting arm movements are attained by mounting the arms 160 on the output shafts of a pivotable air powered actuator 162 and mounting the actuator 162 on the undersides of a pair of blocks 164 which are s'lideably mounted upon a pair of rods 166 mounted upon a pair of anchor blocks 165 so as to extend between the front and the rear of the packing station. The anchor blocks 165 in turn are slideably mounted on a pair of rails 174 so as to allow the use of various size cartons in the packing station.

Rotational movement of the case transfer arms 160 is brought about by the actuator 162. In order to slide the actuator 162 and its associated case transfer arms 160 towards and away from the packing horn 132, a linear two-way cylinder 168 is rigidly mounted by means of a bracket 163 upon the rods 166 in the position best shown in FIG. 2. The linear two-way air cylinder 168 has a shaft 170 which is attached to one of the blocks 164 so that, when the shaft 170 extends, the blocks 164 and hence the arms 160 are caused to slide toward the packing horn 132. Conversely, when-the shaft 170 is retracted, the entire assembly is slid away from the packing horn.

(4) Case Lowering Arm Referring to FIGS. 10 and 11, a lowering arm 176 is provided for causing a packed carton to be placed in an upright position on a conveyor belt disposed below the packing station 24. The arm itself is comprised of a flat tongue portion 178 attached at its rear to a right angle plate 180 which acts to support a corner of the opened carton, these parts being connected under the packing horn 132 so as to allow rotation of the tongue portion 178 from a horizontal position below the packing station to a vertical position adjacent to and contacting the bottom of an opened case while on the packing horn 132; In order that the tongue portion 178 spring upwardly of its own accord when released, a spring 182 is attached to a shaft 184 about which the arm will rotate, so that the arm is biased in an upward direction. The shaft 184 is supported under the packing horn 132 by inserting it into a plate attached under the packing horn. The spring tension, 1 while sufficiently large to raise the arm 176 does not prevent the weight of a packed carton from forcing the tongue portion 178 to its horizontal position under the packing station 24 and above a conveyor. The conveyor, shown in FIGS. 10 and 11, while not part of the invention, nevertheless provides a means for taking packed cartons away from the packing station so the case handling apparatus may automatically open and pack another carton.

PNEUMATIC AND ELECTRICAL CONTROLS FOR THE EXEMPLARY APPARATUS 1. In General The operation of the carton handling apparatus is sequentially controlled through the use of various pneumatic cylinders shown in FIG. 13, and electrical controls shown in FIG. 14.

Air is selectively gated to initiate extension and retraction of the various cylinder shafts by means of solenoid valves 301-307 while vacuum is gated to the carton opening cups 94 by solenoid 300. The air cylinders themselves are of two types, both of which have a two-way action. The linear cylinders are of the kind where air may be gated to either side of a shaft head causing it to extend or retract. The pivotable cylinders are of the type in which, by selectively applying air to one of two inputs, their shafts may be made to turn through a given arc.

Relays R-l through R5, by means of their contact terminals, provide desired holding paths for maintaining power to the various solenoids. The solenoids and relays are located along with miscellaneous control devices in a control box 186 attached to the frame 26.

Electrical switching to the relays and solenoids is accomplished by eight limit switches LS-l through LS-6 and LS-X and LS-Y, the locations of which are shown in FIGS. 1 and 13. Supplementing the limit switches are pressure switches PS-116, PS-154 and PS-l68. These switches are of the type which become actuated by sensing a pressure difference between two points. As shown in FIGS. 13 and 14, each is installed in one of the air lines to its respective cylinder so as to actuate when the pressure in the line reaches a desired magnitude relative to atmospheric pressure. This pressure occurs when the associated cylinder shaft reaches the limit of its travel and the pressure in the cylinder approaches the pressure of the air source.

2. Detailed Description and Operation The operation of the apparatus will be best understood by following a carton as it passes through the apparatus. Referring to FIG. 6, the feeder mechanism 38 is adjusted to receive the desired size of carton blanks, a stack of which are horizontally disposed between the staves 42 so as to be urged by gravity to the loading station where the bottom carton blank will be supported partially by the guide brackets 50 (not shown in FIG. 6) and partially by the carriage bed 54 in preparation for being transferred out.

a. Prepare For Feeding Carton Blank Into Forming Station and Opened Carton Into Packing Station Referring to FIG. 13, and, assuming no case has been left in the apparatus, the carton transfer air cylinder 60 is retracted. Consequently, the case transfer carriage 40 is also retracted so that its rear portion is under the loading station 20 and its forward portion extends into the forming station 22.

The forming station mechanisms are in a position to receive an unopened carton. The carton opening cylinder 108 has its shaft 110 retracted, thereby causing the vacuum cups 94 to be fully withdrawn. The bottom end flap cylinders 116 have the bottom end flap closing arms 114 rotated outwardly toward the front of the forming station 22. The bottom side flap closing cylinders 130 and 130a and the leading top end flap closing cylinder 134 (shown in FIGS. 2 and 9) are in their retracted positions. Referring to FIG. 2, the flap flange cylinder 144 has its shaft 142 extended so as to place the flap flange 140 in a position where it will hold the top leading flap open.

Referring again to FIG. 13, the packing station is now ready to receive an opened carton for packing. The carton positioning cylinder 154 has pivoted the carton positioning arm 152 upwardly to a horizontal position so that an opened carton may pass under it. The carton transfer arms 160 are rotated downwardly to their vertical position by the pivotable cylinder 162, and the case transfer cylinder 168 is retracted to hold the arms near the front of the packing station. The lowering arm 176 is in its lowered position so the tongue portion 178 is disposed horizontally, below the packing station 24 and in a position to allow an opened carton to pass.

b. Feed Carton Blank Into Forming Station Referring to FIG. 14, power for the apparatus is provided in the form of 110-117 volts AC and is supplied by means of a pair of bus lines 410 and 420 through switch 500. The operating sequence is initiated by the transfer of an unopened carton upon the carriage 40 from the loading station 20 to the forming station 22. Referring to FIGS. 6, 7, and 14, the carriage 40 is moved out of the loading station 20 by pushing a cycle/start switch 350 to energize and actuate solenoid 301, thereby gating air to extend the shaft 86 of cylinder connected to the carriage. A holding path to solenoid 301 is established through leg 503 and the normally closed contacts of PS-168 because, as power is applied to solenoid 301, it is also applied to relay R-l, closing its normally open contacts 262 and 264. Referring to FIG. 6, as the carriage 40 moves forward, the anchor plate contacts the rear of the carton blank so as to cause the carton to move with it.

c. Initiate Carton Blank Forming Operations Referring to FIGS. 5 and 7, when the carriage is fully extended, the unopened carton will lie in the forming station 22 under the vacuum cups 94, which are in their retracted positions, ready to be opened. The length of travel of the carriage 40 determines the distance the carton blank will be transferred, but the stop block 92 is positioned in the forming station 22 so as to contact a leading edge and insure the carton does not move too far. The carton is opened by gripping its upper panel and pulling the carton upward into an essentially rectangular tubular configuration, with the carton lying on its side panel in the forming station 22, with its bottom flaps open and pointing toward the front of the forming station. Referring to FIGS. 13 and 14, the vacuum cups 94 are lowered when the movement of the carriage 40 out of the loading station 20 causes the limit switch LS-2 to be actuated, closing its normally opened contacts 261. Through leg 503, the normally closed contacts 263 of LS-S, and the normally closed contacts 274 and 276 of relay R-3, solenoid 302 is enabled, gating air to cylinder 108 to extend its shaft (shown in FIGS. 5 and 7). At the same time vacuum is applied to the vacuum cups 94 through the actuation of solenoid 300.

When the cups have become fully extended, a washer 188 on one of the guide rods 98 (FIG. 13) actuates LS-S. This momentarily opens the normally closed contacts 263 and disables solenoid 302, causing air to be gated to cylinder 108 so that it will retract to withdraw the cups 94 which have gripped the upper panel as shown in FIGS. and 6. At the same time, the normally open contacts 265 of limit switch LS-S are momentarily closed and, through the normally closed contacts 273 of limit switch LS-l, relay R-3 is actuated. The relay R-3 remains actuated through its holding path which is established through leg 505 and its normally open, now closed, contacts 275 and 277. The actuation of relay R3 opens its normally closed contacts 274 and 276, disabling the cups 94-from descending again until relay R-3 drops out prior to the time when another opening sequence is to occur.

Referring to FIGS. 6 and 7, as the cups 94 lift the upper panel away from the bottom of the forming station 22, the retaining fingers 112 act to restrain the bottom panel of the unopened carton so that opening begins. As the upper panel is lifted, the rear panel will contact the angled break plate 111 so that the rear panel is forced forward, causing the carton to have an essentially rectangular tubular configuration when the cups are fully withdrawn. The withdrawal of the cups allows a second washer 190 to actuate limit switch LS-4. This indicates that the carton is fully opened and initiates the bottom flap closing sequence.

In the bottom flap closing sequence, the pivotable cylinders 116 swing the camming arms 114 inwardly to close the bottom end flaps. The withdrawal of the cups 94 and the resulting actuation of limit switch LS-4 closes its normally open contacts 251 in leg 506 to enable solenoid 303 through the normally closed contacts 267 of limit switch LS-6 and the normally open, now closed, contacts 278 and 280 of relay R-3 to gate air to cylinder 116. As the arms 114 cam inwardly and close the bottom end flaps, the elbows 118 contact the forward and rear panels of the opened carton so as to square it in the forming station 22. The forward elbow 118 acts to restrain the forward panel while the top leading flap is opened as described below.

After the bottom end flaps are closed, the next step is to close the bottom side flaps and to fold forward the leading top flap. Referring to FIGS. 13 and 14, when the bottom end flap closing arms 114 become pivoted inwardly, the pressure switch PS-116 in air line 116a is actuated. Line 116a supplies air to cylinder 116 to cause its shaft to rotate the arms 114 inwardly so as to fold the end flaps. When the shaft is fully rotated, pressure builds up in the line, actuating PS-116 which closes its contacts. This allows power to be applied through leg 507 to solenoid 304, gating air to cylinders 130 and 130a so that the closing bars 120 and 120a move in from the top and bottom respectively to contact their respective bottom side flaps and partially close them. This can be best seen in FIG. 8. At the same time, solenoid 304 also gates air to cylinder 134, extending its shaft 136 to open the top leading flap as shown in FIG. 9. A holding path is established in leg 508, since at the same time that solenoid 304 is actuated power is also applied to relay R-4, closing its normally open contacts 286 and 288. The path is completed through the normally closed contacts 253 of LS-3.

At this point, the carton has been fully opened and its bottom flaps are closed, completing the functions to be performed in the forming station. The next step is to initiate transfer of the carton to the packing station 24.

d. Transfer Formed Carton Into Packing Station To provide a clear path for the carton transfer, it is necessary to withdraw the bottom end flap closing arms 1 14. To this end a third washer 192 is located at the top of one of the bottom side flap closing member guide rods to actuate the limit switch LS-6 disabling leg 506 through the opening of the normally closed limit switch contacts 267. Actuation of the limit switch LS-6 disables solenoid 303 shutting off air pressure in line 116a and gating air pressure to air line 116b. The shaft of the bottom end flap cylinders 116 swings the arms 114 away from the carton to remove the elbows from their contact with the forward and rear panels of the carton. Since pressure to line 1 16a is shut off, PS-116 in the air line deactuates and opens, disabling leg 507; however, power is maintained to relay R4 and solenoid 304 through leg 508 as described above. In order to complete the transfer of a carton, the carriage 40 is retracted so as to position the pusher arm 72 against the rear panel of the carton as the carriage moves forward. Because the arm 72 is cammed under the opened carton in the forming station 22 when the carriage is retracted, the bottom side flap closing members 120 and 120a remain extended in order that a projection 123 which is attached to the trailing edge of the lower member 1200 (shown in FIG. 13), will contact the rear of its flap so as to prevent the carton from being dislocated by the cammed arm 72 as the carriage retracts.

Referring to FIG. 14, retraction of the carriage 40 depends on the completion of certain initial operations in a series of operations in the packing station 24 which are performed concurrently with the opening sequence that has just been described. If these initial packing operations, which are performed upon the carton in the packing station have been completed (these operations having yet to be described), pressure switch PS-168 will be actuated and its opened contacts will disable leg 503 and will cut power from the solenoid 301. With its power cut off, solenoid 301 will gate air so that the shaft 86 of cylinder is retracted, taking the carriage 40 with it.

To initiate forward motion of the carriage so as to transfer an unopened carton as well as the opened carton, normally it is not necessary to again push the cycle/start switch 350 because the solenoid 301 will be enabled through leg 502. The normally opened contacts 285 of LS-6 are closed due to the closing member being in its extended position, LS-l was actuated and its normally opened contacts 283 were closed when the carriage was retracted, and the lowering arm 176 is in its down position so that the normally open contacts 287 of LS-X are also closed. As described above, solenoid 301 is again held through leg 503 since at this time PS-168 has closed as a result of the completion of all of the packing station operations.

Referring to FIGS. 6 and 7, as the carriage 40 moves forward, the pusher arm 72 contacts the rear of the opened case in the forming station 22 and causes the carton to be transferred into the packing station 24. Referring to FIG. 9, the flap flange is in a position parallel to the line of travel of the forward leading top in its opened position. Additionally, as can be seenfrom FIG. 11, the lip 158 prevents the leading top flap from entering the horn, the flap coming to rest in a position downstream of the packing horn.

Although the extension of the closing members 120 and 1200 was necessary so as to maintain the bottom side flaps of the carton which is in the forming station in a closed position as the carton moves from the forming station, for the feeding of the carton into the forming station it is necessary that the closing members 120 and 120a be retracted. Referring to FIGS. 13 and 14, as the carriage moves forward it momentarily actuates LS-3. This opens the normally closed contacts 253 of limit switch LS-3 in leg 508 sufficiently long to disable solenoid 304 which, when disabled, gates air to cylinder 130 and 130a in such a manner as to withdraw the closing members 120 and 120a. Although the leading top flap cylinder 134 opened the flap and maintained it in its opened position during the initial part of the carton transfer, its shaft 136 is also withdrawn for the case forming sequence by the disabling of the solenoid 304 through the opening of limit switch contacts 253 of LS-3. With the closing members 120 and 1200 and the flap opening shaft 136 all withdrawn, the forming station is in a condition to accept another unopened carton for forming.

e. Prepare Carton in Packing Station to Receive Goods The operations which are now performed on a carton in the forming station 22 have been described. The operations to be performed on the carton which is transferred into the packing station 24 are to allow the carton to be packed. First, although the opened carton has been moved into the packing station 24, it must be properly positioned in front of the packing horn 132. The carton positioning arm 152 rotates down and pushes the opened carton against the end plate 156. This step is initiated as the carton transfer carriage 40 becomes fully extended, and actuates LS-2, closing the normally opened contacts 261 in leg 503. In addition to enabling the desired cylinders in the forming station, the closing of contacts 261 also enables the solenoid 305 to gate air to line 154a to cause cylinder 154 to pivot the carton transfer arm 152 down against the rear panel of the opened carton in the packing station.

Once having been positioned in front of the packing horn, the opened carton is transferred onto the packing horn. Referring to FIGS. 10, 13, and 14, when the carton transfer am 152 becomes pivoted fully downward, the pressure switch PS-154 in line 154a becomes actuated and its now closed contacts through leg 504 and the normally closed contacts 290 of LS-Y cause solenoid 306 to be actuated. A holding path is established, since relay R-2 is actuated, closing its normally open contacts 266 and 268. The enabling of solenoid 306 causes two things to happen simultaneously. Referring to FIG. 9, air is gated to cylinder 144, retracting its shaft 142 and causing the flap flange 140 to withdraw to a position away from the packing horn 132. This allows the rear top flap to come between the retracted flap flange 140 and the trailing wall of the packing horn. At the same time, air is gated through cylinder 168 extending its shaft 170 to move the support block 164 along the rods 166 in the direction of the arrow 172. This causes the arms 160, which are attached below, to contact the bottom of the opened carton in order to hold its bottom flaps closed and to push the carton onto the horn. The bottom flaps were retained in their closed configuration during the transfer of the carton from the forming station 22 to the packing station 24 by the guide bracket 148 adjustably mounted between the forming station and the packing station. The normally closed terminals 282 and 284 of relay R-4 in leg 503a and the normally closed contacts 270 and 272 of relay R-2 are connected in parallel with PS-168 to insure that any flutter in air line 168a during the time that cylinder 168 is extended does not cause leg 503 to be disabled and withdraw the carriage.

f. Prepare Apparatus For Next Carton Opening and Transfer Sequence Once the opened carton has been transferred onto the packing horn 132, the carton is almost ready to be packed. Before the carton is packed, the apparatus is caused to prepare itself for another carton opening and transfer sequence. As a part of this sequence, the carriage may be retracted, since the carton is supported on the packing horn 132 by the case transfer arms 160, and therefore the carriage 40 is no longer required for support. The retraction of the carriage 40 is conditioned on the case transfer arms 160 becoming fully extended toward the horn 132 by the shaft 170. Pressure switch PS-168 actuates upon full extension of the shaft because it is located in air line 168a which supplies air to extend the shaft. When PS-168 actuates, its contacts open to disable leg 503 and remove power from the solenoid 301. This gates air to cylinder so that retraction of its shaft 86 withdraws the carriage 40.

As the carriage 40 retracts, it deactuates LS2 and the resultant opening of the contact 261 disables solenoid 305. This gates air to cylinder 154 through air line 154b, causing the carton positioning arm 152 to be raised. Since air line 154a has its air supply cut off, PS-154 opens and wont close again until LS-2 is actuated to close its contacts 261.

Thus, the full extension of the case transfer arms toward the horn 132 serves to initiate the retraction of the carriage 40 enabling the case transfer sequence. It also serves indirectly to initiate the raising of the case lowering arm 176 to its vertical position in order that it be ready to perform its function when the carton on the horn has been filled. The latter function is performed by well known components which are therefore not shown. They include a latching electromagnet, a position sensing switch, and a delay device.

Briefly, the lowering arm 176 is retained in its horizontal position against the force of its biasing spring 182 by a latching electromagnet which is deenergized to release the arm 176 into its vertical position. The full extension of the arms 160 toward the horn 132 is sensed by a position sensing switch in the path of the carton as it is pushed onto the hom132 and electrically connected in series with the coil of the latching electromagnet. In order to make sure that the lowering arm 176 is not released until after the carriage 40 has been retracted, a time delay device is connected between the carton sensing switch and the latching electromagnet. The delay is designed to open the circuit to the latching electromagnet a short time after the carriage has cleared the lowering arm 176.

Once the carriage 40 has been retracted and the case lowering arm 176 has been raised into its position against the case upon the horn 132, the carton transfer arms 160 may be moved away from the bottom of the carton so that they will not interfere when the carton is lowered.

Pulling the arms out of the way is initiated when the lowering arm 176 rises to its vertical position where its actuates the limit switch LS-Y. The normally closed contacts 290 of LS-Y in leg 504 open and disable the solenoid 306, gating air to line 168b and causing the cylinder 169 to retract and to pull the arms 160 rectilinearly away from the bottom of the case toward the front of the packing station 24.

The gating of air to line 168b shuts off air in line 168a, dropping the pressure in line 1680. This deactivates PS-l68 and closes its contacts. The closing of PS-l68 provides the holding path when the power is later supplied to solenoid 301 and relay R-2 through leg 502. At the same time, the normally open contacts 292 of LS-Y in leg 509 close and complete a path for current to solenoid 307 which then gates air to cylinder 162, causing the case transfer arms 160 to swing up to a horizontal position. At the same time that solenoid 307 is actuated the relay R-S is also energized and, through its normally opened contacts 294 and 296 and the normally closed contacts 298 of limit switch LS-X in leg 510, holds the power to the solenoid.

g. Pack Goods and Remove Carton The carton having been positioned upon the horn 132, it is next packed by goods shoved into the carton through the horn. The weight of the canned goods in the carton acts to force the lowering arm 176 down against the bias of the spring 182 so as to lower the carton onto the conveyor. The lowering of the carton actuates LS-X and opens its normally closed contacts 298, disabling solenoid 307 and allowing the case transfer arms 160 to swing down to their initial vertical position. This lowering sequence also automatically enables the next carton handling sequence to begin, because the lowering of the transfer arm 176 and the actuation of limit switch LSX close the normally opened contacts 281 on leg 502, again enabling solenoid 301 and gating air to the carriage 40.

From the foregoing it can be seen that there has been described a new and improved packing station for carton handling apparatus. The cartons are automatically removed from a stack and opened. Their bottom flaps are automatically closed and the cartons are moved to a packing station where they are automatically packed and placed in a position for transfer to a downstream position. The sequence of opening the cartons, closing the flaps, and packing canned goods is completely automatic and, since it is sequentially controlled, provides optimum operating speeds for handling cartons.

What is claimed is: j

1. Apparatus for facilitating the packing of goods into a carton having closed bottom flaps and'open top flaps comprising in combination:

a. a horn shaped to enter into said carton and arranged to receive said goods;

b. first means for moving a carton rectilinearly on its side without rotation from a first position to a second position next to said horn where said carton is aligned with its open top facing sideways toward said horn;

c. second means independent of said first means for pushing the carton rectilinearly from said second position onto said horn and for then retracting rectilinearly away from the carton;

. discharge means for moving a moving packed carton away from a position adjacent said horn; and

. pivotal means independent of said first and second means for holding the carton upon said horn when the second means is retracted and for lowering said carton from said horn into an upright position on said discharge means.

2. Apparatus in accordance with claim 1 wherein said horn is generally rectangular with flared walls and wherein the upper wall of said horn terminates in a hinged plate which extends downward into the mouth of said horn to keep out the leading end flap of said carton while it is being conveyed by said first means to its position opposite said horn, said plate being free to swing out of said horn into a horizontal position to permit unimpeded passage of goods into said carton.

3. Apparatus in accordance with claim 1 wherein said pivotal means for holding the carton upon said horn includes an arm mounted to pivot in a vertical plane between an upright position next to the bottom of the carton upon said horn and a horizontal position transversely to and under said first means when the latter is next to said horn and wherein means are provided to cause said first means to shuttle back to said first position after the carton has been pushed onto said horn.

4. A device for positioning a carton on the horn of a packing machine and permitting removal of the filled carton from said horn by the use of means which pivot between a position supporting a carton on the horn and a position below a discharge means to lower the carton from the horn to an upright position on the discharge means comprising:

first means for advancing the carton on its side rectilinearly from a first station to a second station approximately on the same level as said first station and spaced substantially above said discharge means, said box at said second station being in a position opposite the horn with the open top facing the horn;

second means independent of said first means and said pivotal means for pushing the carton rectilinearly from said second station onto said horn;

means for retracting the second means for permitting the pivotal means to lower the carton onto the discharge means; and

means for retracting the first means for permitting the pivotal means to lower the carton onto the discharge means.

5. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said second means holds the carton on the-horn while the first means retracts from said second station to permit the pivotal arm to raise and lower.

6. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said first means is a carriage which supports the carton as it is advanced, said carriage obstructing the path of said pivotal arm when at the second station and clearing the path of said pivotal arm and carton when at said first station and being disposed above said discharge means when at said second station.

flattened configuration at said first station.

9. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said second means pushes the carton substantially perpendicular to the direction the carton is advanced by said first means. 

1. Apparatus for facilitating the packing of goods into a carton having closed bottom flaps and open top flaps comprising in combination: a. a horn shaped to enter into said carton and arranged to receive said goods; b. first means for moving a carton rectilinearly on its side without rotation from a first position to a second position next to said horn where said carton is aligned with its open top facing sideways toward said horn; c. second means independent of said first means for pushing the carton rectilinearly from said second position onto said horn and for then retracting rectilinearly away from the carton; d. discharge means for moving a moving packed carton away from a position adjacent said horn; and e. pivotal means independent of said first and second means for holding the carton upon said horn when the second means is retracted and for lowering said carton from said horn into an upright position on said discharge means.
 2. Apparatus in accordance with claim 1 wherein said horn is generally rectangular with flared walls and wherein the upper wall of said horn terminates in a hinged plate which extends downward into the mouth of said horn to keep out the leading end flap of said carton while it is being conveyed by said first means to its position opposite said horn, said plate being free to swing out of said horn into a horizontal position to permit unimpeded passage of goods into said carton.
 3. Apparatus in accordance with claim 1 wherein said pivotal means for holding the carton upon said horn includes an arm mounted to pivot in a vertical plane between an upright position next to the bottom of the carton upon said horn and a horizontal position transversely to and under said first means when the latter is next to said horn and wherein means are provided to cause said first means to shuttle back to said first position after the carton has been pushed onto said horn.
 4. A device for positioning a carton on the horn of a packing machine and permitting removal of the filled carton from said horn by the use of means which pivot between a position supporting a carton on the horn and a position below a discharge means to lower the carton from the horn to an upright position on the discharge means comprising: first means for advancing the carton on its side rectilinearly from a first station to a second station approximately on the same level as said first station and spaced substantially above said discharge means, said box at said second station being in a position opposite the horn with the open top facing the horn; second means independent of said first means and said pivotal means for pushing the carton rectilinearly from said second station onto said horn; means for retracting the second means for permitting the pivotal means to lower the carton onto the discharge means; and means for retracting the first means for permitting the pivotal means to lower the carton onto the discharge means.
 5. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said second means holds the carton on the horn while the first means retracts from said second station to permit the pivotal arm to raise and lower.
 6. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said first means is a carriage which supports the carton as it is advanced, said carriage obstructing the path of said pivotal arm when at the second station and clearing the path of said pivotal arm and carton when at said first staTion and being disposed above said discharge means when at said second station.
 7. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 and further comprising means for pivoting said second means away from and above the carton when retracted.
 8. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said carton is formed to a tubular configuration from a flattened configuration at said first station.
 9. A device for positioning a carton on the horn of a packing machine in accordance with claim 4 wherein said second means pushes the carton substantially perpendicular to the direction the carton is advanced by said first means. 